Rather than building something entirely new from scratch, Beta Hatch took a brownfield approach, looking to use existing infrastructure and revitalize it. The Cashmere factory is an old juice factory that had been idle for nearly a decade.
In addition to the updated model, the company says its production process is based on a zero-waste system: mealworms are fed organic by-products, and the final ingredients are used in feed and fertilizer.
The plant is partially funded by the Washington State Department of Commerce’s Clean Energy Fund. Through a patented HVAC innovation, excess heat generated by the adjacent data center’s networking equipment is captured and used as the primary heat source to control the environment in the Beta Hatch greenhouse.
”Sustainability is one of the main requirements of insect producers, but it all depends on how they operate. We have some very targeted measures in the production area.
”If you look at the cost and impact of each new piece of steel in a new plant, a brownfield approach can lead to greater efficiency and significant cost savings. All of our electricity comes from renewable sources, and using waste heat also improves efficiency.”
The company’s location next to an apple processing plant means it can use industry by-products, such as pits, as one of its feed substrates: “Thanks to careful site selection, some of our ingredients are transported less than two miles.”
The company also uses dry ingredients from Washington state, which are a byproduct of large wheat processing plants, the CEO said.
And he has “a lot of options” when it comes to substrate feeds. Emery continued that projects are underway with several types of feedstock producers, with the focus being on feasibility studies to determine whether Beta Hatch can scale up waste recycling.
Since November 2020, Beta Hatch has been operating a smaller, gradually expanding manufacturing unit at its Cashmere facility. The company began using the flagship product around December 2021 and has been scaling up its use over the past six months.
”We focused on growing the breeding stock, which is the hardest part of the process. Now that we have a large adult population with good egg production, we are working hard on growing the breeding stock.”
The company is also investing in human resources. “The team has more than doubled in size since August last year, so we are well positioned for further growth.”
This year, a new, separate facility for larval rearing is planned. “We’re just raising money for it.”
The construction is in line with Beta Hatch’s long-term goal of expanding operations using a hub and spoke model. The Cashmere factory will be the hub of egg production, with farms located close to where raw materials are produced.
As for what products will be produced at these dispersed sites, she said manure and whole dried mealworms require minimal handling and can be easily transported from the sites.
”We will likely also be able to process protein powder and petroleum products in a decentralized manner. If a customer requires a more customized ingredient, all dry ground product will be sent to a reprocessor for further processing.”
Beta Hatch is currently producing whole dried insects for use by backyard birds – the protein and oil production is still in the experimental stages.
The company recently conducted trials on salmon, the results of which are expected to be published this year and will form part of a dossier for regulatory approval of the salmon mealworm.
”These data show the success of replacing fishmeal with addition levels of up to 40%. We are now putting a lot of protein and fish oil into development.”
In addition to salmon, the company is working with the industry to gain approval for the use of manure in feed and to expand the use of mealworm ingredients in pet and poultry feed.
In addition, his research group is exploring other uses for insects, such as producing medicines and improving vaccine production.
The round was led by Lewis & Clark AgriFood with strong support from existing investors Cavallo Ventures and Innova Memphis.
Having helped Protix set up the first industrial black soldier fly production facility in the Netherlands, which opened in June, Buhler said he was setting up a new facility for a second insect species, the yellow soldier fly…
This summer, US insect protein producer Beta Hatch will move to a new location to establish a new flagship manufacturing facility and position the company for long-term growth.
Post time: Dec-24-2024